Purified carbon nanotubes and applications thereof

ABSTRACT

The present invention relates to a method of preparing purified carbon nanotubes (CNTs) comprising mixing starting CNTs with an organic solvent in the presence of sonication; substantially removing the organic solvent to obtain a CNT composition; and heating the CNT composition at 200° C. or higher to obtain the purified carbon nanotubes. The present invention further relates to the purified CNTs and cohesive CNT assemblies prepared from the method described herein, and articles (e.g. capacitor, energy storage device or capacitive deionization device) comprising the purified CNTs.

This application is a divisional of U.S. application Ser. No.13/408,884, filed Feb. 29, 2012. The contents of the above identifiedapplication is incorporated herein by reference in its entireties.

TECHNICAL FIELD

This invention relates to methods of preparing purified carbon nanotubes(CNTs). The purified CNTs show high Raman G/D band ratio and highspecific surface area. The purified CNTs are useful as an electrode or acurrent collector for an electrochemical capacitor, energy storagedevice, or capacitive deionization device.

BACKGROUND

Impurities in CNTs appear in multiple forms and are often introducedduring the synthesis of CNTs. In a typical manufacturing process calledalcohol catalytic chemical vapor deposition (ACCVD), evaporated methanolor ethanol vapors come in contact with catalyst particles such as nickelor iron, embedded on magnesium oxide or silica as catalyst support, athigh temperatures inside a furnace. At such conditions, ethanol ormethanol molecules break down, and CNTs start growing around thecatalyst. However, this process also results in the generation ofamorphous carbon, which can be located randomly on the outer surfaces ofCNTs. Amorphous carbon is the most common impurity and the hardest toremove, due to bonding on certain carbon atoms. Other types ofimpurities include catalyst residue such as iron, nickel, etc. andcatalyst support materials such as magnesium oxide and silica. Apartfrom superficial contaminations, another type of defect, structural innature, is caused by sp³ bonded carbon atoms replacing sp² bonds incertain locations down the length of the CNT (FIG. 1). A reasonablylarge concentration of them can also be found at the ends of tubes.

A known technique useful for evaluating the quality of CNTs, i.e., theconcentration of structural defects and amorphous carbon impuritiesincluded therein, is by measuring the intensity ratio of twocharacteristic Raman spectral peaks, called the G/D ratio. The G-band isa tangential shear mode of carbon atoms that corresponds to thestretching mode in the graphite plane. The D-band is a longitudinaloptical (LO) phonon and is known as the disordered or defect mode, as itis a typical sign for defective graphitic structures in CNTs. Whendetermining the quality level of a CNT sample via Raman spectroscopy,the absolute intensities of the G and D band peaks are not particularlyrelevant, and depend greatly on measurement conditions. Rather, theratio of the intensity of the two peaks is the relevant measure. Thecomparison of the ratios of these two peaks' intensities gives a measureof the quality of the CNT samples. Generally, the G/D ratio is used toquantify the structural quality of carbon nanotubes. Thus, CNTs having ahigher G/D indicate a lower amount of defects and a higher level ofquality.

A G/D ratio is typically determined using a Raman spectroscopytechnique. Any of various commercially available instruments may be usedto measure the G and D band intensities and to calculate the G/D ratio.One example of such equipment is available from HORIBA Jobin Yvon Inc.,Edison, N.J., under the model name LabRAM ARAMIS.

In a CNT sample, the G/D ratio is typically changed after purification,i.e., the G/D ratio of the purified CNTs is greater than the G/D ratioof the starting CNTs, indicating that the purified CNTs having fewerstructural defects and/or carbonaceous impurities such as amorphouscarbon.

Various methods of removing amorphous carbon or other carbonaceousimpurities are known in the literature, including thermal oxidation, andvarious solution treatments. However, these methods tend to damage CNTsor cause loss of CNTs. A reported commercial method is the treatment ofCNT with concentrated acid, such as nitric acid, followed by a slow heattreatment. Although this method has been proven to reduce both amorphouscarbon and metallic content, it is unsafe, and a substantial amount ofsuch contaminations can still remain on the surface. Furthermore, acidtreatment is somewhat counterproductive, as it also introducesstructural defects while removing superficial ones.

Therefore, there exists a need for an efficient and safe process forpreparing purified CNTs; the method should efficiently removecarbonaceous impurities without damaging or destroying the CNTs.

SUMMARY OF THE INVENTION

The present invention is directed to a method of preparing purified CNTscomprising: (a) obtaining starting carbon nanotubes having structuraldefects and/or carbonaceous impurities; (b) mixing the starting carbonnanotubes with an organic solvent in the presence of sonication; (c)substantially removing the organic solvent to obtain a carbon nanotubecomposition; and (d) heating the carbon nanotube composition at 200° C.or higher to obtain the purified carbon nanotubes; wherein the organicsolvent is selected from the group consisting of toluene,o-dichlorobenzene (ODCB), isopropyl alcohol (IPA),N,N-dimethylformamide, substituted or unsubstituted benzene,chlorobenzene, m-dichlorobenzene, p-dichlorobenzene, trichlorobenzene,bromobenzene, m-dibromobenzene, o-dibromobenzene, p-dibromobenzene,tribromobenzene, toluene, o-xylene, m-xylene, p-xylene,1,2-dichloroethane, 1,2-dibromoethane, chloroform, primary amines,secondary amines, tertiary amines, dimethyl sulfoxide, and anycombinations thereof.

The present invention is also directed to purified CNTs and/or cohesiveCNT assemblies prepared by the methods described herein.

The present invention is further directed to applications of thepurified CNTs and cohesive CNT assemblies in, e.g. electrical powerstorage and electromagnetic interference shielding. The purified CNTsand cohesive CNT assembly may also be used in an electrode and/or acurrent collector in a capacitor, energy storage device or capacitivedeionization device.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows different types of impurities in CNTs.

FIG. 2 shows (A) the basic structure of an electric double-layercapacitor (EDLC), not to scale, and (B) a schematic diagram of apractical EDLC device, employing the purified CNTs of the currentinvention as capacitor electrodes.

FIG. 3 shows a Raman spectrum of as-received commercial SWCNT material,having an average G/D ratio of 4.9.

FIG. 4 shows a Scanning Electron Microscope (SEM) image of as-receivedSWCNT material.

FIG. 5 shows a SEM image of SWCNT material annealed at 1000° C. for 12hr in argon with 80 ppm oxygen.

FIG. 6 shows a SEM image of SWCNT material mixed and dispersed inisopropanol (IPA), dried at 50° C., and heat treated at 200° C.

FIG. 7 shows a Raman spectrum of SWCNT mixed in IPA, dried at 50° C.,heat-treated at 200° C., and annealed at 750° C.

FIG. 8 shows (A) Raman spectra of SWCNT mixed in IPA, dried, andannealed at different temperatures between 500° C. and 1000° C.; and (B)the variation of Raman G/D ratio with annealing temperature forIPA-dispersed, dried, and annealed SWCNT.

FIG. 9 shows a SEM image of IPA-dispersed SWCNT after annealing at 750°C.

FIG. 10 shows the Raman G/D ratios of SWCNT samples after undergoingvarious dispersing and heat treating procedures.

FIG. 11 shows a Raman spectrum of SWCNT mixed in toluene, dried at 50°C., heat treated at 200° C., and annealed at 750° C.

FIG. 12 shows a SEM image of toluene-dispersed SWCNT dried at 50° C. andheat treated at 200° C.

FIG. 13 shows SEM images at two magnifications (×50,000 and ×100,000) oftoluene-dispersed SWCNT dried at 50° C., heat treated at 200° C., andannealed at 750° C.

DETAILED DESCRIPTION OF THE INVENTION

The inventors have discovered a novel method for preparing purifiedcarbon nanotubes, or CNTs. The method allows removing all (or nearlyall) carbonaceous impurities without degrading or damaging the CNTs. Themethod results in CNTs having a very high G/D ratio. The G/D ratio ofthe purified CNTs in general is at least 5 fold, 10 fold, 15 fold, or 20fold higher than that of the starting CNTs.

The method comprises the steps of: (a) obtaining starting carbonnanotubes having structural defects, carbonaceous impurities, or both;(b) mixing the starting carbon nanotubes with an organic solvent in thepresence of sonication; (c) substantially removing the solvent to obtaina carbon nanotube composition; and (d) heating the carbon nanotubecomposition at 200° C. or higher to obtain the purified CNTs. As usedherein, the term “substantially removing the solvent” means removingmore than 90% of the solvent, preferably removing more than 95%, morethan 97%, or more than 99% of the solvent.

The starting CNTs comprise single-wall carbon nanotubes (SWCNTs),double-walled carbon nanotubes (DWCNTs), multi-walled carbon nanotubes(MWCNTs), or any combination thereof. In a preferred embodiment, thestarting CNTs are selected from the group consisting of SWCNTs, DWCNTs,and the combination thereof.

The starting CNTs have structural defects and/or carbonaceousimpurities, typically detectable as a D-band in Raman spectroscopicmeasurement. In one embodiment, the starting CNTs are obtained in a formof powder, particles, flakes, loose agglomerates, or any appropriateforms that can be dispersed in the organic solvent. In anotherembodiment, the starting CNTs may be ground, pulverized, or mechanicallyaltered in one or more standard techniques to obtain the starting CNTsin an appropriate form before being mixed with the solvent. For example,CNTs may be purchased from a commercial source, such as SWCNTs availablefrom Thomas Swan and Co., Ltd (Consett, County Durham, United Kingdom)under the product name “Elicarb SW.” These CNTs are supplied in the formof wetcake (loose agglomerates in an aqueous mixture) or as dryparticles. The dry particles, which are typically smaller than 5 mm inthe largest dimension, may be used as-received in the purificationprocess. Optionally, these CNTs may be ground into smaller particles orpowder and then used in the purification process. The wetcake materialmay be dried by any standard method, then mechanically broken apart intoparticles or loose agglomerates, and then used in the purificationprocess. Optionally the dried wetcake material may be further groundinto smaller particles or powder, and then used in the purificationprocess. In general, the powder, particles, flakes, or looseagglomerates of the starting CNTs are smaller than 1 cm, preferablysmaller than 3 mm, and more preferably smaller than 1 mm in the largestdimension.

The organic solvent used in the method is selected from the groupconsisting of toluene, o-dichlorobenzene (ODCB), isopropyl alcohol(IPA), N,N-dimethylformamide, substituted or unsubstituted benzene,chlorobenzene, m-dichlorobenzene, p-dichlorobenzene, trichlorobenzene,bromobenzene, m-dibromobenzene, o-dibromobenzene, p-dibromobenzene,tribromobenzene, toluene, o-xylene, m-xylene, p-xylene,1,2-dichloroethane, 1,2-dibromoethane, chloroform, primary amines,secondary amines, tertiary amines, dimethyl sulfoxide, and anycombinations thereof.

The preferred solvent comprises toluene, o-dichlorobenzene, isopropylalcohol, N,N-dimethylformamide, or any combination thereof. The morepreferred solvent is toluene.

In step (b), the ratio of the starting CNTs and the solvent is betweenabout 0.01-100 mg/ml, preferably 0.1-10 mg/ml, for example, about 1mg/ml. “About,” as used in this application, refers to +/−10% of therecited value.

Mixing the starting CNTs with the solvent in step (b) may be carried outat a suitable temperature under a suitable pressure wherein the solventis in a liquid form, i.e. between the melting point and the boilingpoint of the solvent under the suitable pressure. In one embodiment, thestarting CNTs are dispersed in the solvent at a temperature between 0°C. and 110° C., between ambient room temperature (defined as about 20°C.) and about 45° C. or between 10° C. and 30° C. Ambient roomtemperature and pressure are typically suitable conditions.

In certain embodiments, the purification method further comprises mixingthe starting CNTs and the solvent by a second mechanical agitationmethod before, during, and/or after step (b), and before step (c). Anystandard mechanical agitation methods known in the art can be used.Examples include, without limitation, mechanical stiffing, and/or highshear mixing, and/or microfluidization. In one embodiment, themechanical agitation is high-shear mixing and is conducted during step(b).

Mixing of the starting CNTs with the solvent may be carried out in thepresence of one or more types of mechanical agitation and/or sonication.The mixing step may comprise more than one periods of mechanicalagitation. In each period, one or more types of mechanical agitationand/or sonication may be carried out. The same type of mechanicalagitation and/or sonication carried out at different periods may havethe same or different parameters.

Mechanical agitation may be carried out at a suitable rotational mixingspeed (e.g. about 500 rpm to about 50,000 rpm) with a high shear mixercomprising a rotor or impeller, together with a stationary componentknown as a stator, or an array of rotors and stators. The mixer is usedin a tank containing the carbon starting material and the organicsolvent mixture to be mixed or in a pipe through which the mixturepasses, to create shear. In one embodiment, a two-stage mixing processstarting at a first speed (e.g. about 10,000 rpm) for a first timeperiod (e.g. about 30 minutes) followed by a second speed (e.g. about5,000 rpm) for a second time period (e.g. about 10 minutes) is adopted.

Sonication may be carried out by a variety of methods using commerciallyavailable equipment; examples include, without limitation, an ultrasonicprocessor with a probe or wand, and an ultrasonic bath or tank.Sonication may be carried out for a suitable time period at a suitableenergy level at a suitable temperature. In one embodiment, the suitabletime period is between about 0.1 and about 100 hours, between about 0.1and about 10 hours, between about 1 and about 4 hours, or about 160minutes. The suitable energy level is at least 0.01 watt/gram ofsolvent, or between 0.16 watt/gram of solvent and about 1.6 watt/gram ofsolvent. The suitable temperature is the same as described supra.

In one embodiment, the mixing step comprises three periods of sonicationand/or mechanical agitation. For example, the first period compriseshigh shear mixing at 10,000 rpm for 30 minutes in the presence ofsonication, the second period comprises high shear mixing at 5,000 rpmfor 10 minutes in the presence of sonication, and the third periodcomprises sonication for 2 hours at 45° C.

In a preferred embodiment, the mixing step comprises at least one periodof sonication in the presence of high shear mixing.

In step (c), the solvent of the mixture is substantially removed, forexample, by heating the CNT-solvent mixture above ambient roomtemperature, to evaporate the solvent. The heating temperature in step(c) may be between ambient room temperature and about 200° C., orbetween ambient room temperature and about 100° C. Heating may beaccomplished in any suitable manner, such as in a convection oven or ona hot plate. In another embodiment, the solvent is removed byevaporation in a controlled manner at ambient room temperature. In yetanother embodiment, the solvent is removed by evaporation under avacuum.

Typically, greater than 99% of the solvent is removed by evaporationduring step (c). The solvent removed in step (c) may be collected. Forexample, a liquid nitrogen trap can be used to collect the removedorganic solvent. The recovered organic solvent may be reused in themethod directly or after purification if necessary.

Solvent removal step (c) may be performed at greater than ambientpressure (about 760 Torr), at ambient pressure, or at lower than ambientpressure. In certain embodiments, step (c) is performed at a pressurebetween about 760 Torr and 0.001 Torr, or between about 760 Torr and0.01 Torr. For example, during step (c), the pressure may initially beambient pressure, and gradually be decreased to a minimum pressure of0.01 Torr. During this step, the pressure may be reduced gradually suchthat no boiling or bubbling of solvent is observed.

Step (d) is performed at a suitable temperature at 200° C. or higher, or500° C. or higher, or at 600° C. or higher, for a suitable time periodin a suitable atmosphere.

In certain embodiments, step (d) is performed at a temperature of about200-1100° C., preferably about 400-1100° C., about 600-1000° C., orabout 600-900° C.

In certain embodiments, step (d) is performed for a time period betweenabout 10 minutes and about 100 hours, preferably between about 30minutes and 30 hours, more preferably between about 1 hour and about 15hours.

In certain embodiments, step (d) is performed in an atmospherecomprising between about 1 ppm and about 25% oxygen, preferably betweenabout 1 ppm and 10,000 ppm oxygen, more preferably between about 20-2000ppm oxygen, and still more preferably, between about 20-200 ppm. Incertain embodiments, step (d) is performed in an atmosphere in which thenon-oxygen content comprises at least 99% inert gases (e.g. argon,helium, nitrogen, or any combination thereof).

For example, step (d) is performed at about 750° C. for about 12 hoursin an atmosphere comprising at least 99% argon and between about 20-2000ppm oxygen.

The present invention is also directed to a method of preparing purifiedCNTs having high specific surface area. As used herein “CNTs having highspecific surface area” means CNTs having a BET (Brunauer-Emmett-Teller)specific surface area of about 800 m²/g or higher, preferably about1,000 m²/g or higher, more preferably about 1200 m²/g or higher. Themethod comprises the steps of: (a1) obtaining starting CNTs; (b1) mixingthe starting CNTs with an organic solvent comprising toluene in thepresence of sonication and high shear mixing, to produce a dispersion;(c1) substantially removing the organic solvent by evaporation to obtaina CNT composition; and (d1) heating the CNT composition between about200-1100° C. in a substantially inert atmosphere comprising 1-10,000 ppmoxygen.

In certain embodiments, the mixing step (b1) is performed byconcurrently high-shear mixing and sonicating the mixture of CNT andtoluene for a period of about 10 minutes to about 20 hours, preferablyfor a period of about 20 minutes to about 8 hours.

In certain embodiments, the mixing step (b1) is performed in twosub-steps (b1-a) and (b1-b). In these embodiments, sub-step (b1-a) isperformed by concurrently high-shear mixing and sonicating the mixtureof CNT and toluene for a period of about 10 minutes to about 2 hours,preferably about 20 minutes to about 1 hour, more preferably about 40minutes. Sub-step (b1-b) is performed by sonicating the mixture of CNTand toluene, with or without the presence of mechanical mixing (such ashigh-shear mixing), for a period of about 10 minutes to about 6 hours,preferably about 1 to 3 hours, more preferably about 2 hours.

In solvent removal step (c1), the organic solvent is substantiallyremoved by evaporation, for example, by heating the CNT-solvent mixtureat a temperature above ambient room temperature. In another embodiment,the organic solvent is removed by evaporation at ambient roomtemperature in a controlled manner.

Solvent removal step (c1) may be performed at greater than ambientpressure (about 760 Torr), at ambient pressure, or at lower than ambientpressure. In certain embodiments, step (c1) is performed at a pressurebetween about 760 Torr and 0.001 Torr, or between about 760 Torr and0.01 Torr. For example, during step (c1), the pressure may initially beambient pressure, and gradually be decreased to a minimum pressure of0.01 Torr. During this step, the pressure may be reduced gradually suchthat no boiling or bubbling of solvent is observed.

In certain embodiments, the heating step (d1) is performed at about200-1100° C., preferably about 400-1100° C., about 600-1000° C., orabout 600-900° C., in a substantially inert atmosphere comprising1-10,000 ppm oxygen, preferably 20-2000 ppm oxygen.

For example, step (d1) is performed at about 750° C. for about 12 hoursin an atmosphere comprising at least 99% argon and about 20 to about2000 ppm oxygen.

In the above methods for preparing purified CNTs and for preparingpurified CNTs with high surface area, certain parameters can be selectedso that the purified CNTs are in a form of cohesive carbon nanotubeassembly. The parameters include (a) mixing the starting CNTs and theorganic solvent in a prescribed ratio that will result in dispersion ofthe CNTs in the organic solvent, and (b) removing the organic solvent ina controlled manner.

A cohesive carbon nanotube (CNT) assembly is defined herein as aself-assembled monolithic structure in which the CNTs are uniformlydistributed; the cohesive CNT assembly has a distinct shape and sizethat is free-standing. The cohesive CNT assembly is further defined inthat it does not adhere to any other material or surface, has sufficientmechanical strength and integrity that it does not require mechanicalsupport by any other material, nor does it require the presence of abinder material to retain its strength and integrity. The cohesive CNTassembly can be a film, a wafer, a free-standing film, a free-standingwafer, a film attached to a substrate or a wafer attached to asubstrate.

In one embodiment, the prescribed ratio of the starting CNTs to theorganic solvent is about 0.01-100 mg per ml of solvent, about 0.01-50 mgper ml of solvent, about 0.05-50 mg per ml of solvent, about 0.1-20 mgper ml of solvent, about 0.1-10 mg per ml of solvent, about 0.5-5 mg perml of solvent, or about 1-2 mg per ml of solvent.

In order for the cohesive CNT assembly to form, the solvent must beremoved in a controlled manner. Examples of a controlled manner ofremoving solvent may include slow evaporation, slow draining of thesolvent from the container, or any combination thereof. It is importantnot to remove the solvent so rapidly that will disturb or prevent theCNTs from forming a cohesive monolith. It is also important not toagitate the mixture during the removal process.

Examples of a non-controlled manner of removing the solvent includepouring off the organic solvent by tipping the container (decanting),boiling of the solvent, and direct physical removal of the liquid at orthrough its exposed top surface in the container (e.g., by suctioning orsiphoning through a tube or pipe).

The specific conditions for controlled removal of solvent that willresult in the formation of a cohesive CNT assembly depend on the type ofthe starting CNTs and the solvent, and can be determined experimentally.For example, the solvent is removed by evaporation at a suitablepressure, at a suitable temperature, and within a suitable time. Thesuitable pressure may be about 5,000-0.001 Torr, about 1,500-0.01 Torr,or about 760-0.01 Torr. The suitable temperature may be about −20-200°C., about 20-180° C., or about 40-80° C. The suitable time may bebetween about 10 seconds and about 100 hours, between about 1 minute andabout 100 hours, between about 10 minutes and about 40 hours, or betweenabout 1 and about 20 hours.

The evaporation of solvent may alternatively be controlled by monitoringthe evaporation rate of the solvent and maintaining it within a rangethat will not prevent or disturb the formation of the assembly. Theevaporation of solvent typically follows the classic and well-knowntheory of two-stage drying of porous bodies first proposed by Thomas K.Sherwood in “The Drying of Solids—I”, Industrial Engineering andChemistry 21, 1 (1929), 12-16, and in “The Drying of Solids—II”,Industrial Engineering and Chemistry 21, 10 (1929), 976-980. During thefirst evaporation stage, the evaporation rate is preferably about0.01-10 milliliters/minute (ml/min), more preferably about 0.10-1.0ml/min. During the second evaporation stage, the evaporation rate isabout 5×10⁻⁵-5×10⁻² ml/min, more preferably about 5×10⁴-7×10⁻³ ml/min.

The present invention is also directed to the purified CNTs prepared bythe purification methods described herein. The purified CNTs have higherRaman G/D ratios and/or higher BET specific surface area compared to thestarting CNTs.

In one embodiment, the purified CNTs have a Raman G/D ratio of at least9, at least 20, at least 40, at least 50, or at least 80. In certainembodiments, the G/D ratio of the starting CNTs is between about 2 andabout 8, or between about 4 and about 6.

In another embodiment, the purified CNTs have a BET specific surfacearea of about 800 m²/g or higher. In another embodiment, the purifiedCNTs have a BET specific surface area of about 1,000 m²/g or higher. Ina preferred embodiment, the purified CNTs have a BET specific surfacearea of about 1,200 m²/g or higher.

In another embodiment, the weight of the purified CNTs is about 10% toabout 95% of that of the CNT composition obtained after the removal ofthe solvent (step (c) or (c1)) and before the heating of the CNTcomposition (step (d) or (d1)) in the methods described herein,preferably about 30% to about 90%, more preferably about 50% to about80%.

In another embodiment, the purified CNTs have Raman G/D ratio of about20 or higher, and BET specific surface area of about 800 m²/g or higher.Preferably, the purified CNTs have Raman G/D ratio of about 20 orhigher, and BET surface area of about 1000 m²/g or higher. Morepreferably, the purified CNTs have Raman G/D ratio of about 20 orhigher, and BET surface area of about 1200 m²/g or higher. Still morepreferably, the purified CNTs have Raman G/D ratio of about 50 orhigher, and BET surface area of about 1200 m²/g or higher.

The present invention also relates to the cohesive CNT assembly preparedfrom the methods described herein. The cohesive CNT assembly has higherRaman G/D ratio and/or higher BET specific surface area compared to thestarting CNTs.

In one embodiment, the cohesive CNT assembly has a Raman G/D ratio of atleast 9, at least 20, at least 40, at least 50, or at least 80.

In another embodiment, the cohesive CNT assembly has a BET specificsurface area of about 800 m²/g or higher. In another embodiment, thecohesive CNT assembly has a BET specific surface area of about 1,000m²/g or higher. In a preferred embodiment, the cohesive CNT assembly hasa BET specific surface area of about 1,200 m²/g or higher.

In another embodiment, the weight of the cohesive CNT assembly is about10% to about 95% of that of the CNT composition obtained after theremoval of the solvent (step (c) or (c1)) and before the heating of theCNT composition (step (d) or (d1)) in the methods described herein,preferably about 30% to about 90%, more preferably about 50% to about80%.

In another embodiment, the cohesive CNT assembly has a Raman G/D ratioof about 20 or higher, and a BET specific surface area of about 1,000m²/g or higher. In a preferred embodiment, the cohesive CNT assembly hasa Raman G/D ratio of about 20 or higher, and a BET surface area of about1200 m²/g or higher. In a more preferred embodiment, the cohesive CNTassembly has a Raman G/D ratio of about 50 or higher, and a BET surfacearea of about 1200 m²/g or higher.

The present invention is further directed to an article comprising thepurified CNTs prepared by the methods described herein. The cohesive CNTassembly prepared from the purified CNTs is especially useful in makingan electrode or a current collector for a capacitor, an energy storagedevice, or a capacitive deionization device.

In one embodiment, the article is an energy storage device comprising acurrent collector and an electrode on one side of an insulatingmaterial, and another current collector and another electrode on theother side of the insulating material, wherein at least one of theelectrodes and/or at least one of the current collectors comprises thepurified CNTs prepared according to the methods described herein. Incertain embodiments, the purified CNTs may be the cohesive CNT assemblydescribed herein.

In another embodiment, the article is an energy storage devicecomprising a current collector and an electrode on one side of anelectrolyte, and another current collector and another electrode on theother side of the electrolyte, wherein at least one of the electrodesand/or at least one of the current collectors comprises the purifiedCNTs prepared according to the methods described herein. In certainembodiments, the purified CNTs may be the cohesive CNT assemblydescribed herein.

In another embodiment, the article is an electrochemical double-layercapacitor (EDLC) comprising a current collector and an electrode on oneside of an electrolyte, another current collector and another electrodeon the other side of the electrolyte, and a separator between the twosets of current collectors and electrodes, wherein at least one currentcollector or electrode comprises the purified CNTs prepared according tothe methods described herein. In certain embodiments, the purified CNTsmay be the cohesive CNT assembly described herein. The basic structureof an EDLC employing cohesive CNT assembly described herein as theelectrodes is shown in FIG. 2(A). A schematic diagram of a practicalEDLC device employing cohesive CNT assembly described herein as theelectrodes is shown in FIG. 2(B).

In another embodiment, the article is an EDLC as described above,wherein at least one current collector or electrode comprises thepurified CNTs prepared according to the methods described herein, forwhich the measured specific capacitance is greater than about 50Farad/gram, and the −45° complex impedance phase angle frequency isgreater than about 5 Hz. In certain embodiments, the purified CNTs maybe the cohesive CNT assembly described herein.

In another embodiment, the article is a capacitive deionization(desalination) device comprising (a) a current collector and anelectrode on one side of a spacer; and (b) another current collector andanother electrode on the other side of the spacer, wherein at least oneof the electrodes and/or at least one of the current collectorscomprises the purified CNTs prepared according to the methods describedherein. In certain embodiments, the purified CNTs may be cohesive CNTassembly described herein.

The invention is illustrated further by the following examples that arenot to be construed as limiting the invention in scope to the specificprocedures or products described therein.

EXAMPLES Example 1 As-Received SWCNT Thermally Treated at 750° C. and1000° C.

Dry particles of single-wall carbon nanotubes (SWCNT) were acquired fromThomas Swan and Co., Ltd (Consett, County Durham, United Kingdom) underthe product name “Elicarb SW.” Nine samples of SWCNT were randomly takenfrom the as-received material and each was measured for Raman G/D ratiousing a LabRam ARAMIS Raman Microscope manufactured by Horiba JobinYvon, Edison, N.J., with a 532-nm (green) laser. The average G/D ratiowas about 4.9 with standard deviation of 1.3 (27%). A representativeRaman spectrum of the as-received Thomas Swan SWCNT material is shown inFIG. 3. Three-point Lorentzian peak-fitting was used to determine the Gband intensity (i.e., the area under the G band portion of thespectrum), and single-point peak fitting was used to determine the Dband intensity (i.e., the area under the D band portion of thespectrum).

About 500 mg of the as-received SWCNT particles were placed in a quartzboat and heat treated at 200° C. for 3 hours in a convection oven. Theaverage G/D ratio of the SWCNT after this heat treatment was again about4.9, very close to that of the as-received SWCNT.

About 250 mg of 200° C.-treated SWCNT particles were placed in a quartzboat, which was then placed inside a 2-inch diameter quartz tubefurnace, which was then sealed and purged with argon gas containingabout 80 ppm oxygen for 2 hours at a flow rate of 0.51 liter/min. Then,the furnace was heated at 250° C./hour to 750° C. and held there for 12hours, while continuing the gas flow. After cooling to room temperatureat 300° C./hr, nine samples (about 10 mg each) of SWCNT were randomlytaken from the 750° C.-treated (annealed) material and their Ramanspectra were obtained. The average G/D ratio was about 8.2 with standarddeviation of 1.5 (18%).

Another 250 mg of 200° C.-treated SWCNT particles in a quartz boat wereannealed at 1000° C. under otherwise identical conditions as describedfor the 750° C. treatment. The average G/D ratio of this material wasabout 8.9 with standard deviation of 1.3 (15%).

Modest increases in Raman G/D ratio from 4.9 to 8.2 and 8.9 wereobserved after annealing the samples at 750° C. and 1000° C.,respectively. Scanning electron microscope (SEM) (Model JSM-7500F, JEOLLtd., Tokyo) images of as-received and 1000° C.-annealed SWCNT are shownin FIG. 4 and FIG. 5, respectively. SWCNT annealed at 750° C. (notshown) appeared similar to that of SWCNT annealed at 1000° C. Largeamounts of amorphous carbon are visible among both as-received andannealed SWCNT in the SEM images.

Raman G/D ratio and BET specific surface area determined by nitrogenadsorption/desorption analysis (Model TriStar 3000, MicromeriticsInstrument Corp., Norcross, Ga.) of as-received, 200° C.-treated, and750° C.- and 1000° C.-annealed SWCNT are shown in Table 1. A slightincrease in G/D ratio occurred after annealing at 750° C. and 1000° C.BET surface areas of the SWCNT samples thermally treated at differenttemperatures were essentially the same, around 800 m²/gram.

TABLE 1 Raman G/D ratio and BET surface area of as-received SWCNT andSWCNT after thermal treatment at different temperatures. Thermaltreatment Raman BET surface SWCNT Material conditions G/D ratio area(m²/g) As-received — 4.9 805 Treated at 200° C. 3 hr, air 4.9 798Annealed at 750° C. 12 hr, 80 ppm oxygen 8.2 801 Annealed at 1000° C. 12hr, 80 ppm oxygen 8.9 840

Example 2 SWCNT Mixed and Dispersed in Solvent, Dried, and Heat-Treatedat 200° C.

250 mg of as-received SWCNT and 250 ml of isopropyl alcohol (IPA)(2-propanol, catalog #A416, Fisher Scientific, Pittsburgh, Pa.) werecombined in a beaker. The beaker's contents were mixed using a highshear mixer (Model Me-100LC, Charles Ross & Son Company, Hauppauge,N.Y.) for 30 minutes at 10,000 RPM and an additional 10 minutes at 5,000RPM, while the beaker was ultra-sonicated in a water bath (Model:FS7652, Fisher Scientific). After the 40-minute high shear mixing wascompleted, ultra-sonication was continued for an additional two hours.

Then, the contents of the beaker were transferred to five separate 9-cmdiameter Kimax® glass dishes, with each dish containing about 50 mlsolvent and about 50 mg SWCNT. Prior to dispensing the solvent-SWCNTmixture into the dishes, each dish was first rinsed with 10 ml of ahydrophobic (HP) treatment solution for about 5 seconds, then dried atroom temperature for 30 minutes to evaporate any remaining HP solution,then heated at 200° C. in a convection oven for 1 hr. The water contactangle of the HP-treated glass dish surface was about 110° at roomtemperature. The composition of the hydrophobic treatment solution isdescribed in U.S. Pat. No. 6,395,331 B1 to Yan et al, which is herebyincorporated by reference.

Each container was tightly covered with clear plastic wrap, the wrap waspunched with 20 pin-holes, and the container was placed in a convectionoven at 50° C. After all solvent was evaporated (in about 10-30 hr),each sample was further heat treated at 200° C. for 3 hr. The driedSWCNT material was then collected and stored in separate vials foranalysis by Raman spectroscopy, nitrogen adsorption/desorption (BET),and SEM.

The above procedures for combining, mixing, drying, and heat treatingwere repeated identically using six other solvents including: toluene(Fisher Scientific catalog #T324), isooctane (2,2,4-trimethylpentane,#AC42198), N,N-dimethylformamide (#D119), reagent alcohol (#A995),1-butanol (#A399), and o-dichlorobenzene (ODCB) (#02231-1).

After the drying step at 50° C., most of the dried SWCNT was in powderform or in fragments. Dried SWCNT pre-dispersed in ODCB and tolueneformed completely intact cohesive assemblies, or wafers, about 9 cm indiameter with thickness of about 15 μm.

Raman G/D ratio and BET surface area of the dried samples are shown inTable 2. SWCNT mixed and dispersed in solvent, dried at 50° C., andheated at 200° C. generally showed higher Raman G/D ratio than that ofas-received (non-dispersed) SWCNT annealed at 750° C. (or 1000° C.).SWCNT dispersed in solvent, dried, and treated at 200° C. showed similaror slightly lower BET surface area than that of as-received SWCNT. AnSEM image of IPA-dispersed and 200° C.-dried SWCNT is shown in FIG. 6.

TABLE 2 Effect of solvents used to disperse SWCNT on the G/D ratio andBET surface area after drying at 200° C. in air. Solvent used for RamanBET surface dispersing SWCNT G/D ratio area (m²/g) Isopropanol (IPA)11.9 720 Toluene 10.6 663 Isooctane 8.2 — N,N-Dimethylformamide 11.8 —Reagent alcohol 9.4 — 1-Butanol 12.7 — o-dichlorobenzene (ODCB) 10.5 718As received 4.9 798 As received, 750° C. treated 8.2 801

Example 3 SWCNT Dispersed in IPA and Annealed at 500° C.-1000° C.

About 250 mg of SWCNT were mixed and dispersed in about 250 ml IPA anddried at 50° C., then heat treated at 200° C. for 3 hr in air, asdescribed in Example 2. The 200° C.-treated SWCNT had an average RamanG/D ratio of 11.9.

About 50 mg each of the 200° C.-treated SWCNT were then annealed at 500,600, 750, and 1000° C. for 12 hr using the same quartz boat, quartz tubefurnace, purge gas, and heating and cooling rates as described inExample 1. The average Raman G/D ratios of the annealed SWCNT are shownin Table 3.

TABLE 3 Effect of 12-hr annealing temperature on G/D ratio ofIPA-dispersed SWCNT. Annealing Raman temperature G/D Ratio None (200°C.-treated) 11.9 500° C. 39.1 600° C. 76.9 750° C. 139.7 1000° C.  130.0

FIG. 7 shows the Raman spectrum of the IPA-dispersed SWCNT afterannealing at 750° C. FIG. 8 (A) shows the Raman spectra of SWCNT mixedin IPA, dried, and annealed at different temperatures. FIG. 8 (B) showsthe variation of G/D ratio of IPA-dispersed SWCNT annealed at differenttemperatures. FIG. 9 shows an SEM image of IPA-dispersed SWCNT afterdrying, heat treating at 200° C., and annealing at 750° C. An SEM imageof IPA-dispersed SWCNT dried and heat treated at 200° C. was previouslyshown in FIG. 6.

It is evident from the Raman G/D data and SEM images that this methodproduced a very clean SWCNT material. G/D ratio consistently increasedwith annealing temperature up to 750° C., then decreased slightly after1000° C. annealing. Annealing at 1000° C. caused a substantial loss ofmaterial, with the remaining amount being about half of that present atthe start of thermal treatment. This indicates that annealing at 1000°C. consumed some portion of SWCNT, in addition to removing carbonaceousimpurities. The optimum temperature for this annealing or thermaltreatment seemed to be lower than 1000° C. SEM images also showedremarkably clean SWCNT bundles after annealing at 750° C. (FIG. 9), withonly a slight trace of amorphous carbon or other impurity materials,which were distinctly visible between nanotube bundles in the materialheated to only 200° C. (FIG. 6). It is apparent that the significantincrease in G/D ratio and notable improvement in microscopic appearanceof the SWCNT after 750° C. treatment go hand-in-hand.

Example 4 SWCNT Mixed in IPA with High Shear Mixing and No Sonication

About 250 mg of SWCNT and about 250 ml of IPA were combined in a beaker.The contents of the beaker were mixed using a high shear mixer for 30minutes at 10,000 RPM and an additional 10 minutes at 5,000 RPM. Noconcurrent ultra-sonication was used. After high shear mixing, thecontents of the beaker were allowed to stand for 30 minutes.

About 50 ml of the contents were cast into each of five 9-cm diameterglass dishes previously treated with HP solution as described in Example2. Each dish was covered with plastic wrap, the wrap was punched with 20pin-holes, and the dishes were dried at 50° C. in a convection oven forabout 30 hr. Then, the wrap was removed and the five dried SWCNT sampleswere further heated in the convection oven at 200° C. for 3 hr. Thedried and heat-treated SWCNT had an average Raman G/D ratio of 11.4.

The SWCNT samples were then annealed at 750° C. for 12 hr as describedin Example 1, after which their average Raman G/D ratio increased to15.9. Mechanical stiffing by high shear mixing, without accompanyingsonication, followed by annealing at 750° C., resulted in only a slightincrease in G/D ratio from 4.9 to 15.9.

Example 5 SWCNT Mixed in IPA with Sonication and No High Shear Mixing

About 250 mg of SWCNT and about 250 ml of IPA were combined in a beaker.The beaker and its contents were ultra-sonicated in a water bath for 2hr. No mechanical mixing was applied to the mixture of SWCNT and IPA.

After sonication, the mixture was separately cast into five glassdishes, dried at 50° C., and heat treated at 200° C. as described inExample 5. The dried SWCNT had an average Raman G/D ratio of 6.6.

The SWCNT samples were then annealed at 750° C. for 12 hr as describedin Example 1, after which their average Raman G/D ratio increased to79.0. Sonication of SWCNT in IPA without accompanying high shear mixing,followed by annealing at 750° C. resulted in a moderately substantialincrease in G/D ratio from 4.9 to 79.0.

The above procedure was repeated identically, except the beaker and itscontents were ultra-sonicated for 6 hr rather than 2 hr. After 200° C.heat-treatment, the average G/D ratio of the SWCNT was 8.7. After 750°C. annealing, the average G/D ratio of the SWCNT was 118. This furtherillustrated that sonication without high shear mixing resulted in amoderate to substantial improvement in G/D ratio.

Table 4 summarizes the effects of various methods of dispersing SWCNT inIPA (described in Examples 1, 3, 5, and 6) on the resulting Raman G/Dratio, after annealing at 750° C. High shear mixing alone provided onlya slight increase in G/D ratio, while ultra-sonication provided amoderate to substantial increase. Overall, the greatest increase in G/Dratio was achieved through the combination of high shear mixing andultra-sonication.

TABLE 4 Effect of dispersing method on Raman G/D ratio of SWCNTdispersed in IPA, and annealed at 750° C. Raman Dispersing Method G/DRatio As-received, non-dispersed SWCNT (Example 1) 4.9 High shear mixing40 min, no ultra-sonication (Example 4) 15.9 Ultra-sonication 2 hr, nohigh shear mixing (Example 5) 79.0 Ultra-sonication 6 hr, no high shearmixing (Example 5) 118 High shear mixing 40 min + Ultra-sonication 2 hr139.7 (Example 3)

The effects of the various dispersing methods are also illustrated inFIG. 10. Most notably, the effects are not readily apparent from the G/Dratios of the SWCNT samples after drying and heat treating at 200° C.The wide range of G/D ratio and the effects of the different dispersingmethods could be observed only after the annealing treatment at 750° C.

Example 6 SWCNT Dispersed in Toluene and Annealed at 750° C.

About 250 mg of as-received SWCNT were mixed and dispersed in about 250ml toluene, dried at 50° C., then heat treated at 200° C. for 3 hr inair, following procedures identical to those described in Example 2. Thetoluene-dispersed and dried SWCNT was in the form of intact cohesive9-cm diameter wafers, weighing about 50 g each. The 200° C.-treatedSWCNT had a Raman G/D ratio of about 10.6. One 50-gram sample of 200°C.-treated SWCNT was annealed at 750° C. for 12 hr using the sameprocedures described in Example 1, except a 7-inch quartz tube furnacewas used, and the purging time prior to annealing was 6 hours. The RamanG/D ratio of the 750° C.-annealed SWCNT was 68.3, and the BET surfacearea was 1616 m²/g. FIG. 11 shows the Raman spectrum of SWCNT mixed intoluene, dried, and then annealed at 750° C., with three-point andone-point Lorentzian peak-fitting used to evaluate the G and D bandintensities, respectively. FIG. 12 shows an SEM image of SWCNT mixed anddispersed in toluene, dried at 50° C., and heat treated at 200° C. FIG.13 shows SEM images of the same toluene-treated SWCNT after annealing at750° C., at two magnifications.

The Raman data and SEM images clearly indicate that this procedureproduced SWCNT material with both substantially increased G/D ratio andremarkably clean nanotube bundles, with little, if any, visibleamorphous carbon or other impurity materials, which were clearly visiblebetween the bundles in as-received or 200° C.-treated material.Furthermore, the SWCNT mixed and dispersed in toluene, then annealed at750° C., showed unexpectedly high BET surface area of 1616 cm²/g, whichis about double that of the as-received SWCNT (Example 1).

Example 7 SWCNT Dispersed in Different Solvents and Annealed at 750° C.

SWCNT samples were prepared in the same manner described in Example 6,except using six different solvents other than toluene. The solventsincluded isooctane, isopropanol (IPA), N,N-dimethylformamide, reagentalcohol, 1-butanol, and o-dichlorobenzene (ODCB). Table 5 shows theaverage Raman G/D ratio and BET surface area of the SWCNT prepared ineach of the solvents, after the step of heat treating at 200° C., andthen after the step of annealing at 750° C.

Raman G/D ratio increased substantially after annealing at 750° C., forSWCNT dispersed in toluene, IPA, N,N-dimethylformamide, or ODCB.Isooctane, reagent alcohol, and 1-butanol were less effective atincreasing the G/D ratio of 750° C.-annealed SWCNT. SWCNT dispersed intoluene and annealed at 750° C. showed unexpectedly high BET surfacearea, which was not observed with any other solvent used.

TABLE 5 Effect of solvent used to disperse SWCNT on the G/D ratio andBET surface area after heat treating at 200° C., and after annealing at750° C. After 200° C. After 750° C. heat treatment (Ex. 2) annealingRaman BET Raman BET Dispersing Solvent G/D ratio (m²/g) G/D ratio (m²/g)Isopropanol 11.9 720 139.7 759 Toluene (Ex. 6) 10.6 663 68.3 1616Isooctane 8.2 — 14.2 803 N,N-Dimethylformamide 11.8 — 71.0 848 Reagentalcohol 9.4 — 11.4 845 1-Butanol 12.7 — 17.8 904 o-dichlorobenzene 10.5718 134 926 As received SWCNT 4.9 798 8.9 801 (Ex. 1)

Example 8 Toluene-Dispersed SWCNT Wafers Annealed in 10,000 Ppm (1%)Oxygen

About 420 mg SWCNT were combined with about 280 ml toluene in a beaker.The combined materials were then mixed by high-shear mixing andsonication as described in Example 2. The dispersion was then cast intofive HP-treated glass dishes, with each dish containing about 84 mgSWCNT and 56 ml toluene. After drying at 50° C. and heat-treating at200° C., five intact SWCNT cohesive assemblies (wafers) were obtained,each weighing about 84 mg and having thickness of about 25 μm.

The above procedure was repeated five more times resulting in 30 intactcohesive CNT wafers.

Three wafers each, randomly selected from the 30 wafers, were thenannealed at 300, 350, 400, 450, and 500° C., respectively for 48 hoursin a quartz tube furnace under the same conditions described in Example6, except that instead of argon gas with about 80 ppm oxygen, nitrogengas containing about 10,000 ppm oxygen was used as the purging andannealing gas. Three wafers each were also annealed at 500° C. for 3hours and 12 hours. After annealing, average Raman G/D ratio and BETsurface area were determined for each set of annealing conditions.

As shown in Table 6, percent weight loss, Raman G/D ratio, and BETsurface area all increased with increasing 48-hr annealing temperaturebetween 300 and 450° C. This is attributed to greater amounts ofamorphous carbon, defects, and/or other carbonaceous impurities beingremoved from the CNTs with increasing temperature, under otherwisesimilar conditions. BET surface area of greater than 1000 m²/g wasachieved at a 48-hr annealing temperature of 400° C.

Significant jumps in weight loss and G/D ratio were observed whenannealing temperature was increased to 500° C., suggesting that muchgreater amounts of amorphous carbon were removed compared to annealingat lower temperatures. However, under these conditions it appears thatsome carbon nanotube combustion occurred as well, as the surface areaslightly decreased.

Reducing the annealing time at 500° C. from 48 hours down to 12 or 3hours resulted in less weight loss and some decrease in G/D ratio, but asubstantial increase in BET surface area to 1358 m²/g This indicatesthat amorphous carbon removal was still substantial while combustion ofCNTs was somewhat reduced.

Based on these results, there appeared to be a relation between weightloss in annealing and the final BET surface area of the CNTs. When theweight loss in annealing was about 20% or greater, toluene-dispersedSWCNT achieved BET specific surface area of greater than 1000 m²/g.Surface area reached a maximum when the weight loss was about 70%, andthen decreased when the weight loss was higher than about 70%.

TABLE 6 Weight loss, G/D ratio and BET surface area of SWCNT wafersannealed at different temperatures and time under ~10,000 ppm oxygen innitrogen. Annealing Annealing Weight Raman BET surface Temperature (°C.) Time (hr) loss (%) G/D ratio area (m²/g) 300 48 2.8 10.2 845 350 484.1 10.4 905 400 48 18.8 11.2 1010 450 48 28.5 16.3 1141 500 48 84.561.2 1102 500 12 77.2 45.7 1273 500 3 71.8 37.6 1358

Example 9 Toluene-Dispersed SWCNT Wafers, 12-Hr Annealed Under VariousAtmospheres

Cohesive SWCNT wafers were prepared as described in Example 8, throughthe 200° C.-heating step.

Three wafers each were then annealed at 700, 800, 900, and 1000° C. for12 hours in a quartz tube furnace using the conditions described inExample 6, except the furnace atmosphere was ultra-high-purity argonwith about 0.5 ppm oxygen. Under these annealing conditions, Raman G/Dratio and BET surface area showed only slight increases compared to theun-annealed material (Table 7). Weight loss was substantially lowercompared to that of similar material annealed under higher oxygencontent (Examples 4, 80 ppm, and Example 8, 10,000 ppm). Oxygenconcentration of 0.5 ppm was insufficient to remove amorphous carbon andother impurities within the range of temperatures and timesinvestigated.

Three wafers each were then annealed at 500° C. and 600° C. in anatmosphere of ultra-high-purity (UHP) dry air, containing 21% oxygen.Only about 5 wt % of the material remained after 500° C. annealing, butthis material had very high G/D ratio, indicating complete removal ofcarbonaceous impurities (Table 8). The sample annealed at 600° C. wascompletely combusted.

TABLE 7 Weight loss, G/D ratio, and BET surface area of toluene-dispersed SWCNT annealed for 12 hr at different temperatures under UHPargon with 0.5 ppm oxygen. Oxygen Balance Weight loss BET content inafter Raman surface Temperature in furnace annealing G/D area (° C.)furnace gas (%) ratio (m²/g) 700 0.5 ppm argon 5.5 9.0 714 800 0.5 ppmargon 6.7 11.7 729 900 0.5 ppm argon 11.3 11.8 797 1000 0.5 ppm argon19.2 9.2 856

TABLE 8 Weight loss, G/D ratio, and BET surface area of toluene-dispersed SWCNT annealed for 12 hr at different temperatures under dryair with 21% oxygen. Oxygen Balance Weight loss BET content in afterRaman surface Temperature in furnace annealing G/D area (° C.) furnacegas (%) ratio (m²/g) 200 (Ex. 2) 21% dry air — 10.6 663 500 21% dry air95.1 >1480 — 600 21% dry air 100.0 — —

TABLE 9 Weight loss, G/D ratio, and BET surface area of toluene-dispersed SWCNT annealed for 12 hr at different temperatures under UHPargon with 1000 ppm oxygen. Oxygen Balance Weight loss BET content inafter Raman surface Temperature in furnace annealing G/D area (° C.)furnace gas (%) ratio (m²/g) 500 1000 ppm argon 61.0 30.6 1366 600 1000ppm argon 74.6 51-197 — 750 1000 ppm argon 82.0 >430 —

Three wafers each were then annealed at 500, 600, and 750° C. in UHPargon containing about 1000 ppm oxygen. Material loss and Raman G/Dratio increased consistently with annealing temperature, indicating thatremoval of amorphous carbon and other carbon impurities increased withtemperature (Table 9). However, the high weight losses indicated thatsome amount of CNT was also combusted under these conditions. High BETsurface area of 1366 m²/g was achieved for the sample annealed at 500°C. in 1000 ppm oxygen.

Example 10 EDLC Devices Utilizing SWCNT Electrodes

SWCNT cohesive assemblies (wafers) were fabricated following the mixing,dispersing, drying, and 200° C.-heating steps described in Example 2,using ODCB or toluene as the dispersing solvent. Some of the wafers werethen annealed at different temperatures under different oxygen amounts,as shown in Table 9.

The wafers were then evaluated for their performance as electrodes inElectrochemical Double-Layer Capacitors (EDLCs). Fabrication andevaluation of EDLC devices utilizing SWCNT wafer electrodes wereconducted at JME Inc. (Shaker Heights, Ohio). Symmetric EDLC “coin-cell”devices were fabricated by using pairs of disk-shaped electrodes (0.625inch in diameter) both cut from the same SWCNT wafer. Prior toassembling into coin cells, the electrodes were dried under vacuum at60° C. for 12 hours. EDLC coin cell fabrication was performed inside adry box, with moisture level maintained below 20 ppm (by volume) duringcoin cell assembly. The separator material, made by Nippon Kodoshi Corp.(Kochi, Japan), had a thickness of about 25 μm. Propylene carbonate (PC)with 1.0 M tetraethylammonium-tetrafluoroborate (TEA-TFB) salt was usedas the electrolyte. Aluminum metal plates were clamped against eachconductive face-plate and used as current collectors. The performancedata for EDLC devices utilizing SWCNT electrodes are shown in Table 10.

EDLC devices fabricated using SWCNT wafers derived from toluenedispersions, and annealed at 550, 600, or 750° C., showed performancesuperior to that of devices fabricated using either ODCB-dispersed SWCNTwafers, or toluene-dispersed SWCNT wafers that were not annealed above200° C. EDLCs fabricated from toluene-dispersed and annealed SWCNT waferelectrodes all showed −45° complex impedance phase angle frequency above5 Hz, and specific capacitance above 50 Farad/gram. EDLCs fabricatedfrom other wafers showed frequency lower than 5 Hz, and specificcapacitance lower than 50 Farad/gram.

TABLE 10 Performance of EDLC devices utilizing SWCNT wafers dispersed indifferent solvents and annealed under different conditions. EDLCProperties SWCNT Electrode Fabrication −45° phase Annealing (12 hr) BETangle Dispersion Temp. Oxygen surface frequency Capacitance solvent (°C.) (ppm) area (m²/g) G/D ratio (Hz) (F/g) ODCB (none) 718 10.5 2.2 42ODCB 750° C. 80 926 134 1.2 48 Toluene (none) 663 10.6 4.2 37 Toluene550° C. 150 1323 14.3 8.5 59 Toluene 600° C. 150 1380 17.3 9.3 53Toluene 750° C. 150 1765 32.5 6.2 55

What is claimed is:
 1. An energy storage device comprising a currentcollector and an electrode on one side of an insulating material or anelectrolyte, and another current collector and another electrode on theother side of the insulating material or the electrolyte, wherein atleast one of the electrodes and/or at least one of the currentcollectors comprises purified carbon nanotubes having a Raman G/D ratioof at least 50 and a BET specific surface area of 1200 m²/g or higher.2. The energy storage device according to claim 1, wherein the purifiedcarbon nanotubes have a Raman G/D ratio of at least
 80. 3. The energystorage device according to claim 1, wherein the purified carbonnanotubes are prepared by a method comprising the steps of: (a) mixingstarting carbon nanotubes with an organic solvent in the presence ofsonication to produce a dispersion; (b) substantially removing theorganic solvent to obtain a carbon nanotube composition; and (d) heatingthe carbon nanotube composition at 200° C. or higher in an atmospherecomprising between about 1 ppm to 10,000 ppm of oxygen; wherein theorganic solvent is selected from the group consisting of toluene,o-dichlorobenzene, isopropyl alcohol, N,N-dimethylformamide, substitutedor unsubstituted benzene, chlorobenzene, m-dichlorobenzene,p-dichlorobenzene, trichlorobenzene, bromobenzene, m-dibromobenzene,o-dibromobenzene, p-dibromobenzene, tribromobenzene, o-xylene, m-xylene,p-xylene, 1,2-dichloroethane, 1,2-dibromoethane, chloroform, primaryamines, secondary amines, tertiary amines, dimethyl sulfoxide, and anycombinations thereof.
 4. A capacitive deionization device comprising acurrent collector and an electrode on one side of a spacer, and anothercurrent collector and another electrode on the other side of the spacer,wherein at least one of the electrodes and/or at least one of thecurrent collectors comprises purified carbon nanotubes having a RamanG/D ratio of at least 50 and a BET specific surface area of 1200 m²/g orhigher.
 5. The capacitive deionization device according to claim 4,wherein the purified carbon nanotubes have a Raman G/D ratio of at least80.
 6. The capacitive deionization device according to claim 4, whereinthe purified carbon nanotubes are prepared by a method comprising thesteps of: (a) mixing starting carbon nanotubes with an organic solventin the presence of sonication to produce a dispersion; (b) substantiallyremoving the organic solvent to obtain a carbon nanotube composition;and (d) heating the carbon nanotube composition at 200° C. or higher inan atmosphere comprising between about 1 ppm to 10,000 ppm of oxygen;wherein the organic solvent is selected from the group consisting oftoluene, o-dichlorobenzene, isopropyl alcohol, N,N-dimethylformamide,substituted or unsubstituted benzene, chlorobenzene, m-dichlorobenzene,p-dichlorobenzene, trichlorobenzene, bromobenzene, m-dibromobenzene,o-dibromobenzene, p-dibromobenzene, tribromobenzene, o-xylene, m-xylene,p-xylene, 1,2-dichloroethane, 1,2-dibromoethane, chloroform, primaryamines, secondary amines, tertiary amines, dimethyl sulfoxide, and anycombinations thereof.
 7. An electrochemical double-layer capacitor(EDLC) comprising two electrodes, an electrolyte, and a separator,wherein at least one electrode comprises purified carbon nanotubeshaving a Raman G/D ratio of at least 50 and a BET specific surface areaof 1200 m²/g or higher, for which a measured specific capacitance isgreater than 50 Farad/gram, and a −45° complex impedance phase anglefrequency is greater than 5 Hz.
 8. The EDLC according to claim 7,wherein the purified carbon nanotubes have a Raman G/D ratio of at least80.
 9. The energy storage device according to claim 1, wherein thepurified carbon nanotubes are in a form of a cohesive carbon assembly.10. The capacitive deionization device according to claim 4, wherein thepurified carbon nanotubes are in a form of a cohesive carbon assembly.11. The EDLC according to claim 7, wherein the purified carbon nanotubesare in a form of a cohesive carbon assembly.
 12. The EDLC according toclaim 7, wherein the purified carbon nanotubes are prepared by a methodcomprising the steps of: (a) mixing starting carbon nanotubes with anorganic solvent in the presence of sonication to produce a dispersion;(b) substantially removing the organic solvent to obtain a carbonnanotube composition; and (d) heating the carbon nanotube composition at200° C. or higher in an atmosphere comprising between about 1 ppm to10,000 ppm of oxygen; wherein the organic solvent is selected from thegroup consisting of toluene, o-dichlorobenzene, isopropyl alcohol,N,N-dimethylformamide, substituted or unsubstituted benzene,chlorobenzene, m-dichlorobenzene, p-dichlorobenzene, trichlorobenzene,bromobenzene, m-dibromobenzene, o-dibromobenzene, p-dibromobenzene,tribromobenzene, o-xylene, m-xylene, p-xylene, 1,2-dichloroethane,1,2-dibromoethane, chloroform, primary amines, secondary amines,tertiary amines, dimethyl sulfoxide, and any combinations thereof.